COMMON ELECTRIC ARC WELDING PROCESSES

COMMON ELECTRIC ARC WELDING PROCESSES

2.1 INTRODUCTION After much experimentation by others in the early 1800's, an Englishman named Wilde obtained the first electric welding patent in 1865. He successfully joined two small pieces of iron by passing an electric current through both pieces producing a fusion weld. Approximately twenty years later, Bernado, a Russian, was granted a patent for an electric arc welding process in which he maintained an arc between a carbon electrode and the pieces to be joined, fusing the metals together as the arc was manually passed over the joint to be welded. 2.1.0.1 During the 1890's, arc welding was accomplished with bare metal electrodes that were consumed in the molten puddle and became part of the weld metal. The welds were of poor quality due to the nitrogen and oxygen in the atmosphere forming harmful oxides and nitrides in the weld metal. Early in the Twentieth Century, the importance of shielding the arc from the atmosphere was realized. Covering the electrode with a material that decomposed in the heat of the arc to form a gaseous shield appeared to be the best method to accomplish this end. As a result, various methods of covering electrodes, such as wrapping and dipping, were tried. These efforts culminated in the extruded coated electrode in the mid-1920's,greatly improving the quality of the weld metal and providing what many consider the most significant advance in electric arc welding .2.1.0.2 Since welding with coated electrodes is a rather slow procedure, more rapid welding processes were developed. This lesson will cover the more commonly used electric arc welding processes in use today .

2.2

SHIELDED METAL ARC WELDING

Shielded Metal Arc Welding*, also known as manual metal arc welding, stick welding, or electric arc welding, is the most widely used of the various arc welding processes. Welding is performed with the heat of an electric arc that is maintained between the end of a coated metal electrode and the work piece (See Figure 1). The heat produced by the arc melts the base metal, the electrode core rod, and the coating. As the molten metal droplets are transferred across the arc and into the molten weld puddle, they are shielded from the atmosphere by the gases produced from the decomposition of the flux coating. The molten slag floats to the top of the weld puddle where it protects the weld metal from the atmosphere during solidification. Other functions of the coating are to provide arc stability and control bead shape. More information on coating functions will be covered in subsequent part .*Shielded Metal Arc Welding (SMAW) is the terminology approved by the American Welding Society.

2.2.1 Equipment & Operation One reason for the wide acceptance of the SMAW process is the simplicity of the necessary equipment. The equipment consists of the following items. (SeeFigure 2) 1.Welding power source 2.Electrode holder 3.Ground clamp 4.Welding cables and connectors 5.Accessory equipment (chipping hammer, wire brush) 6.Protective equipment (helmet, gloves, etc.)

.2.2 Welding Power Sources - Shielded metal arc welding may utilize either alternating current (AC) or direct current (DC), but in either case, the power source selected must be of the constant current type. This type of power source will deliver a relatively constant amperage or welding current regardless of arc length variations by the operator (. The amperage determines the amount of heat at the arc and since it will remain relatively constant, the weld beads produced will be uniform in size and shape. 2.2.2.1 Whether to use an AC, DC, or AC/DC power source depends on the type of welding to be done and the electrodes used. The following factors should be considered: 1. Electrode Selection - Using a DC power source allows the use of a greater range of electrode types. While most of the electrodes are designed to be used on AC or DC, some will work properly only on DC. 2. Metal Thickness - DC power sources may be used for welding both heavy sections and light gauge work. Sheet metal is more easily welded with DC because it is easier to strike and maintain the DC arc at low currents. 3. Distance from Work - If the distance from the work to the power source is great ,AC is the best choice since the voltage drop through the cables is lower than with DC. Even though welding cables are made of copper or aluminum (both good conductors), the resistance in the cables becomes greater as the cable length increases. In other words, a voltage reading taken between the electrode and the work will be somewhat lower than a reading taken at the output terminals of the power source. This is known as voltage drop. 4. Welding Position ) - DC may be operated at lower welding currents, it is more suitable for overhead and vertical welding than AC. AC can successfully be used for out-of-position work if proper electrodes are selected .5. Arc Blow - When welding with DC, magnetic fields are set up throughout the weldment. In weldments that have varying thickness and protrusions, this magnetic field can affect the arc by making it stray or fluctuate in direction. This condition is especially troublesome when welding in corners. AC seldom causes this problem because of the rapidly reversing magnetic field produced.

2.2.2.2 Combination power sources that produce both AC and DC are available and provide the versatility necessary to select the proper welding current for the application. 2.2.2.3 When using a DC power source, the question of whether to use electrode negative or positive polarity arises. Some electrodes operate on both DC straight and reverse polarity, and others on DC negative or DC positive polarity only. Direct current flows in one direction in an electrical circuit and the direction of current flow and the composition of the electrode coating will have a definite effect on the welding arc and weld bead. Figure 3 shows the connections and effects of straight and reverse polarity. 2.2.2.4 Electrode negative (-) produces welds with shallow penetration; however, the electrode meltoff rate is high. The weld bead is rather wide and shallow as shown at "A" in Figure 3. Electrode positive (+)produces welds with deep penetration and a narrower weld bead as shown at"B" in Figure 3.

2.2.2.5 While polarity affects the penetration and burn-off rate, the electrode coating also has a strong influence on arc characteristics. Performance of individual electrodes will be discussed .2.2.3 Electrode Holder - The electrode holder connects to the welding cable and con-ducts the welding current to the electrode. The insulated handle is used to guide the electrode over the weld joint and feed the electrode over the weld joint and feed the electrode into the weld puddle as it is consumed. Electrode holders are available in different sizes and are rated on their current carrying capacity. 2.2.4 Ground Clamp - The ground clamp is used to connect the ground cable to the work piece. It may be connected directly to the work or to the table or fixture upon which the work is positioned. Being a part of the welding circuit, the ground clamp must be capable of carrying the welding current without overheating due to electrical resistance. 2.2.5 Welding Cables - The electrode cable and the ground cable are important parts of the welding circuit. They must be very flexible and have a tough heat-resistant insulation. Connections at the electrode holder, the ground clamp, and at the power source lugs must be soldered or well crimped to assure low electrical resistance. The cross-sectional area of the cable must be sufficient size to carry the welding current with a minimum of voltage drop .Increasing the cable length necessitates increasing the cable diameter to lessen resistance and voltage drop. The table in Figure 4 lists the suggested American Wire Gauge (AWG)cable size to be used for various welding currents and cable lengths. 2.2.6 Coated Electrodes - Various types of coated electrodes are used in shielded metal arc welding. Electrodes used for welding mild or carbon steels are quite different than those used for welding the low alloys and stainless steels. Details on the specific types will be covered in subsequent part

2.3 GAS TUNGSTEN ARC WELDING

Gas Tungsten Arc Welding* is a welding process performed using the heat of an arc established between a non consumable tungsten electrode and the work piece. See Figure 5.The electrode, the arc, and the area surrounding the molten weld puddle are protected from the atmosphere by an inert gas shield. The electrode is not consumed in the weld puddle as in shielded metal arc welding. If a filler metal is necessary, it is added to the leading the molten puddle as shown in 2.3.0.1Gas tungsten arc welding produces exceptionally clean welds no slag is produced, the chance inclusions in the weld metal is and the finished weld requires virtually no cleaning. Argon and Helium, the primary shielding gases employed, are inert gases. Inert gases do not chemically combine with other elements and therefore, are used to exclude the reactive gases, such as oxygen and nitrogen, from forming compounds that could be detrimental to the weld metal.

2.3.0.2 Gas tungsten arc welding may be used for welding almost all metals mild steel ,low alloys, stainless steel, copper and copper alloys, aluminum and aluminum alloys, nickel and nickel alloys, magnesium and magnesium alloys, titanium, and others. This process is most extensively used for welding aluminum and stainless steel alloys where weld integrity is of the utmost importance. Another use is for the root pass (initial pass) in pipe welding, which requires a weld of the highest quality. Full penetration without an excessively high inside bead is important in the root pass, and due to the ease of current control of this process, it lends itself to control of back-bead size. For high quality welds, it is usually necessary to provide an inert shielding gas inside the pipe to prevent oxidation of the inside weld bead.*Gas Tungsten Arc Welding (GTAW) is the current terminology approved by the American Welding Society, 2.3.0.3Gas tungsten arc welding lends itself to both manual and automatic operation. In manual operation, the welder holds the torch in one hand and directs the arc into the weld joint .The filler metal is fed manually into the leading edge of the puddle. In automatic applications, the torch may be automatically moved over a stationary work piece or the torch may be stationary with the work moved or rotated in relation to the torch. Filler metal, if required, is also fed automatically

.2.3.1 EQUIPMENT AND OPERATION - Gas tungsten arc welding may be accomplished with relatively simple equipment, or it may require some highly sophisticated components. Choice of equipment depends upon the type of metal being joined, the position of the weld being made, and the quality of the weld metal necessary for the application. The basic equipment consists of the following: 1.The power source 2.Electrode holder (torch) 3.Shielding gas 4.Tungsten electrode 5.Water supply when necessary 6.Ground cable 7.Protective equipment Figure 6 shows a basic gas tungsten arc welding schematic.

2.3.2 Power Sources - Both AC and DC power sources are used in gas tungsten arc welding. They are the constant current type with a drooping volt-ampere curve. This type of power source produces very slight changes in the arc current when the arc length (voltage) is varied. The choice between an AC or DC welder depends on the type and thickness of the metal to be welded. Distinct differences exist between AC and DC arc characteristics, and if DC is chosen, the polarity also becomes an important factor. The effects of polarity in GTAW are directly opposite the effects of polarity in SMAW as described in paragraphs 2.2.2.3through 2.2.2.5. In SMAW, the distribution of heat between the electrode and work, which determines the penetration and weld bead width, is controlled mainly by the ingredients in the flux coating on the electrode. In GTAW where no flux coating exists, heat distribution between the electrode and the work is controlled solely by the polarity. The choice of the proper welding current will be better understood by analyzing each type separately. The chart in Figure 7

WELDING CURREN

2.3.2.2 Direct current electrode negative (DCEN) is produced when the electrode is connected to the negative terminal of the power source. Since the electrons flow from the electrode to the plate, approximately 70% of the heat of the arc is concentrated at the work, and approximately 30% at the electrode end. This allows the use of smaller tungsten electrodes that produce a relatively narrow concentrated arc. The weld shape has deep penetration and is quite narrow. See Figure 8. Direct current electrode negative is suitable for welding most metals. Magnesium and aluminum have a refractory oxide coating on the surface that must be physically removed immediately prior to welding if DCSP is to be used. 2.3.2.3 Direct current electrode positive (DCEP) is produced when the electrode is connected to the positive terminal of the welding power source. In this condition, the electrons flow from the work to the electrode tip, concentrating approximately 70% of the heat of the arc at the electrode and 30% at the work. This higher heat at the electrode necessitates using larger diameter tungsten to prevent it from melting and contaminating the weld metal. Since the electrode diameter is larger and the heat is less concentrated at the work, the resultant weld bead is relatively wide and shallow. See Figure 8. 2.3.2.4 Aluminum and magnesium are two metals that have a heavy oxide coating that acts as an insulator and must be removed before successful welding can take place. Welding with electrode positive provides a good oxide cleaning action in the arc. If we were to study the physics of the welding arc, we find that the electric current causes the shielding gas atoms to lose some of their electrons. Since electrons are negatively charged, these gas atoms now are unbalanced and have an excessive positive charge. As we learned in Lesson I, unlike charges attract. These positively charged atoms (or positive ions as they are known in chemical terminology) are attracted to the negative pole, in this case the work, at high velocity. Upon striking the work surface, they dislodge the oxide coating permitting good electrical conductivity for the maintenance of the arc, and eliminate the impurities in the weld metal that could be caused by these oxides

.2.3.2.5 Direct current electrode positive is rarely used in gas-tungsten arc welding. Despite the excellent oxide cleaning action, the lower heat input in the weld area makes it a slow process, and in metals having higher thermal conductivity, the heat is rapidly conducted away from the weld zone. When used, DCEP is restricted to welding thin sections (under 1/8") of magnesium and aluminum. 2.3.2.6 Alternating current is actually a combination of DCEN and DCEP and is widely used for welding aluminum. In a sense, the advantages of both DC processes are combined, and the weld bead produced is a compromise of the two. Remember that when welding with60 Hz current, the electron flow from the electrode tip to the work reverses direction 120 times every second. Thereby, the intense heat alternates from electrode to work piece, allowing the use of an intermediate size electrode. The weld bead is a compromise having medium penetration and bead width. The gas ions blast the oxides from the surface of aluminum and magnesium during the positive half cycle. Figure 8 illustrates the effects of the different types of current used in gas-tungsten arc welding. 2.3.2.7 DC constant current power sources - Constant current power sources, used for shielded metal arc welding, may also be used for gas-tungsten arc welding. In applications where weld integrity is not of utmost importance, these power sources will suffice. With machines of this type, the arc must be initiated by touching the tungsten electrode to the work and quickly withdrawing it to maintain the proper arc length. This starting method contaminates the electrode and blunts the point which has been grounded on the electrode end. These conditions can cause weld metal inclusions and poor arc direction. Using a power source designed for gas tungsten arc welding with a high frequency stabilizer will eliminate this problem. The electrode need not be touched to the work for arc initiation. Instead, the high frequency voltage, at very low current, is superimposed onto the welding current. When the electrode is brought to within approximately 1/8 inch of the base metal, the high frequency ionizes the gas path, making it conductive and a welding arc is established. The high frequency is automatically turned off immediately after arc initiation when using direct current. 2.3.2.8 AC Constant Current Power Source - Designed for gas tungsten arc welding, always incorporates high frequency, and it is turned on throughout the weld cycle to maintain a stable arc. When welding with AC, the current passes through 0 twice in every cycle an arc must be reestablished each time it does so. The oxide coating on metals, such as aluminum and magnesium, can act much like a rectifier as discussed in Lesson I. The positive half-cycle will be eliminated if the arc does not reignite, causing an unstable condition .Continuous high frequency maintains an ionized path for the welding arc, and assures arc re-ignition each time the current changes direction. AC is extensively used for welding aluminum and magnesium.

2.3.2.9 AC/DC Constant Current Power Sources - Designed for gas tungsten arc welding, are available, and can be used for welding practically all metals. The gas tungsten arc welding process is usually chosen because of the high quality welds it can produce. The metals that are commonly welded with this process, such as stainless steel, aluminum and some of the more exotic metals, cost many times the price of mild steel; and therefore, the power sources designed for this process have many desirable features to insure high quality welds. Among these are: 1.Remote current control, which allows the operator to control welding amperage with a hand control on the torch, or a foot control at the welding station. 2.Automatic soft-start, which prevents a high current surge when the arc is initiated. 3.Shielding gas and cooling water solenoid valves, which automatically control flow before, during and for an adjustable length of time after the weld is completed .4.Spot-weld timers, which automatically control all elements during each spot-weld cycle .Other options and accessories are also available. 2.3.2.10 Power sources for automatic welding with complete programmable output are also available. Such units are used extensively for the automatic welding of pipe in position. The welding current is automatically varied as the torch travels around the pipe. Some units provide a pulsed welding current where the amperage is automatically varied between a low and high several times per second. This produces welds with good penetration and improved weld bead shape. 2.3.3 Torches - The torch is actually an electrode holder that supplies welding current to the tungsten electrode, and an inert gas shield to the arc zone. The electrode is held in a collet like clamping device that allows adjustment so that the proper length of electrode protrudes beyond the shielding gas cup. Manual torches are designed to accept electrodes of 3 inch or 7 inch lengths. Torches may be either air or watercooled. The air-cooled types actually are cooled to a degree by the shielding gas that is fed to the torch head through a composite cable. The gas actually surrounds the copper welding cable, affording some degree of cooling. Water-cooled torches are usually used for applications where the welding current exceeds 200 amperes. The water inlet hose is connected to the torch head. Circulating around the torch head, the water leaves the torch via the current-in hose and cable assembly .Cooling the welding cable in this manner allows the use of a smaller diameter cable that is more flexible and lighter in weight. 2.3.3.1 The gas nozzles are made of ceramic materials and are available in various size sand shapes. In some heavy duty, high current applications, metal water-cooled nozzles are used. 2.3.3.2 A switch on the torch is used to energize the electrode with welding current and start the shielding gas flow. High frequency current and water flow are also initiated by this switch if the power source is so equipped. In many installations, these functions are initiated by a foot control that also is capable of controlling the welding current. This method gives the operator full control of the arc. The usual welding method is to start the arc at a low current, gradually increase the current until a molten pool is achieved, and welding begins. At the end of the weld, current is slowly decreases and the arc extinguished, preventing the crater that forms at the end of the weld when the arc is broken abruptly. 2.3.4 Shielding Gases - Argon and helium are the major shielding gases used in gas tungsten arc welding. In some applications, mixtures of the two gases prove advantageous. To a lesser extent, hydrogen is mixed with argon or helium for special applications .2.3.4.1Argon and helium are colorless, odorless, tasteless and nontoxic gases. Both are inert gases, which means that they do not readily combine with other elements. They will not burn nor support combustion. Commercial grades used for welding are 99.99% pure. Argon is .38% heavier than air and about 10 times heavier than helium. Both gases ionize when present in an electric arc. This means that the gas atoms lose some of their electrons that have a negative charge. These unbalanced gas atoms, properly called positive ions, now have a positive charge and are attracted to the negative pole in the arc. When the arc is positive and the work is negative, these positive ions impinge upon the work and remove surface oxides or scale in the weld area. 2.3.4.2 Argon is most commonly used of the shielding gases. Excellent arc starting and ease of use make it most desirable for manual welding. Argon produces a better cleaning action when welding aluminum and

magnesium with alternating current. The arc produced is relatively narrow. Argon is more suitable for welding thinner material. At equal amperage ,helium produces a higher arc voltage than argon. Since welding heat is the product of volts times amperes, helium produces more available heat at the arc. This makes it more suitable for welding heavy sections of metal that have high heat conductivity, or for automatic welding operations where higher welding speeds are required .2.3.4.3 Argon-helium gas mixtures are used in applications where higher heat input and the desirable characteristics of argon are required. Argon, being a relatively heavy gas, blankets the weld area at lower flow rates. Argon is preferred for many applications because it costs less than helium. 2.3.4.4 Helium, being approximately 10 times lighter than argon, requires flow rates of 2 to3 times that of argon to satisfactorily shield the arc. 2.3.5Electrodes - Electrodes for gas tungsten arc welding are available in diameters from .010" to 1/4" in diameter and standard lengths range from 3" to 24". The most commonly used sizes, however, are the .040", 1/16", 3/32", and 1/8" diameters. 2.3.5.1 The shape of the tip of the electrode is an important factor in gas tungsten arc welding. When welding with DCEN, the tip must be ground to a point. The included angle at which the tip is ground varies with the application, the electrode diameter, and the welding current. Narrow joints require a relatively small included angle. When welding very thin material at low currents, a needlelike point ground onto the smallest available electrode maybe necessary to stabilize the arc. Properly ground electrodes will assure easy arc starting ,good arc stability, and proper bead width .2.3.5.2 When welding with AC, grinding the electrode tip is not necessary. When proper welding current is used, the electrode will form a hemispherical end. If the proper welding current is exceeded, the end will become bulbous in shape and possibly melt off to contaminate the weld metal. 2.3.5.3 The American Welding Society has published Specification AWS A5.12- for tungsten arc welding electrodes that classifies the electrodes on the basis of their chemical composition, size and finish. Briefly, the types specified are listed below: 1) Pure Tungsten (AWS EWP) Color Code: Green Used for less critical applications. The cost is low and they give good results at relatively low currents on a variety of metals. Most stable arc when used on AC, either balanced wave or continuous high frequency. 2) 1% Thoriated Tungsten (AWS EWTh-1) Color Code: Yellow Good current carrying capacity, easy arc starting and provide a stable arc. Less susceptible to contamination. Designed for DC applications of nonferrous materials. 3) 2% Thoriated Tungsten (AWS EWTh-2) Color Code: Red Longer life than 1% Thoriated electrodes. Maintain the pointed end longer, used for light gauge critical welds in aircraft work. Like 1%, designed for DC applications for nonferrous materials. 4) .5% Thoriated Tungsten (AWS EWTh-3) Color Code: Blue Sometimes called "striped" electrode because it has 1.0-2.0% Thoria inserted in a wedge-shaped groove throughout its length. Combines the good properties of pureand thoriated electrodes. Can be used on either AC or DC applications. 5) Zirconia Tungsten (AWS EWZr) Color Code: Brown Longer life than pure tungsten. Better performance when welding with AC. Melts more easily than thoriamtungsten when forming rounded or tapered tungsten end. Ideal for applications where tungsten contamination must be minimized. 2.3.6Summary - Gas Tungsten Arc Welding is one of the major welding processes today. The quality of the welds produced and the ability to weld very thin metals are the major features. The weld metal quality is high since no flux is used, eliminating the problem of slag inclusions in the weld metal. It is used extensively in the aircraft and aerospace industry, where high quality welds are necessary and also for welding the more expensive metals where the weld defects become very costly. Metals as thin as .005" can be welded due to the ease of controlling the current.

2.3.6.1The major disadvantages of the process are that it is slower than welding with consumable electrodes and is little used on thicknesses over 1/4" for this reason. Shielding gas and tungsten electrode costs make the process relatively expensive.

2.4 GAS METAL ARC WELDING

Gas Metal Arc Welding* is an arc welding process that uses the heat of an electric arc established between a consumable metal electrode and the work to be welded. The electrode is a bare metal wire that is transferred across the arc and into the molten weld puddle. The*Gas Metal Arc Welding (GMAW) is the current technology approved by the American Welding Society wire, the weld puddle, and the area in the arc zone are protected from the atmosphere by a gaseous shield. Inert gases, reactive gases, and gas mixtures are used for shielding. The metal transfer mode is dependent on shielding gas choice and welding current level. Figure 9i is a sketch of the process showing the basic features. FIGURE 9

2.4.0.1 Gas metal arc welding is a versatile process that may be used to weld a wide variety of metals including carbon steels, low alloy steels, stainless steels, aluminum alloys ,magnesium, copper and copper alloys, and nickel alloys. It can be used to weld sheet metal or relatively heavy sections. Welds may be made in all positions, and the process may be used for semiautomatic welding or automatic welding. In semiautomatic welding, the wire feed speed, voltage, amperage, and gas flow are all preset on the control equipment. The operator needs merely to guide the welding gun along the joint at a uniform speed and hold a relatively constant arc length. In automatic welding, the gun is mounted on a travel carriage that moves along the joint, or the gun may be stationary with the work moving or revolving beneath it. 2.4.0.2 Practically all GMAW is done using DCEP (Electrode positive). This polarity provides deep penetration, a stable arc and low spatter levels. A small amount of GMAW welding is done with DCEN and although the melting rate of the electrode is high, the arc is erratic. Alternating current is not used for gas metal arc welding 2.4.1 Current Density - To understand why gas metal arc welding can deposit weld metal at a rapid rate, it is necessary that the term "current density" be understood. Figure 10shows a 1/4" coated electrode and a 1/16" solid wire drawn to scale. Both are capable of carrying 400 amperes. Notice that the area of the 1/16" wire is only 1/16 that of the core wire of the coated electrode. We can say that the current density of the 1/16" wire is 16 times greater than the current density of the 1/4" wire at equal welding currents. The resultant melt-off rate of the solid wire is very high. If we were to increase the current through the 1/4" coated electrode to increase

the current density, the resistance heating through the 14" electrode length would be excessive, and the rod would become so hot that the coating would crack, rendering it useless. The 1/16" wire carries the high current a distance of less than 3/4", the approximate distance from the end of the contact tip to the arc.

2.4.2Metal Transfer Modes 2.4.2.1Spray transfer is a high current density process that rapidly deposits weld metal in droplets smaller than the electrode diameter. They are propelled in a straight line from the center of the electrode. A shielding gas mixture of Argon with 1% to 2% Oxygen is used for welding mild and low alloy steel, and pure Argon or Argon-Helium mixtures are used for welding aluminum, magnesium, copper, and nickel alloys. Welding current at which spray transfer takes place is relatively high and will vary with the metal being welded, electrode diameter, and the shielding gas being used. Deposition rates are high and welding is usually limited to the flat or horizontal fillet position. See Figure 11

2.4.2.2 Globular transfer takes place at lower welding currents than spray transfer. There is a transition current where the transfer changes to globular even when shielding gases using a high percentage of argon are used. When carbon dioxide (CO2) is used as a shielding gas ,the transfer is always globular. In globular transfer, a molten drop larger than the electrode diameter forms on the end of the electrode, moves to the outer edge of the electrode and falls into the molten puddle. Occasionally, a large drop will "short circuit" across the arc, causing the arc to extinguish momentarily, and then instantaneously reignite. As a result, the arc is somewhat erratic, spatter level is high, and penetration shallow. Globular transfer is not suitable for outof-position welding. See Figure 11

2.4.2.3 Short circuiting transfer is a much used method in gas metal arc welding. It is produced by using the lowest current-voltage settings and the smaller wires, usually .030",.035", and .045" diameters. The low heat input makes this process ideal for sheet metal, out-of-position work, and poor fit-up applications. Often called "short arc welding" because metal transfer is achieved each time the wire actually short circuits (makes contact) with the weld puddle. This happens very rapidly. It is feasible for the short circuit frequency to be 20200times a second, but in practice, it occurs from 90-100 times a second. Each time the electrode touches the puddle, the arc is extinguished. It happens so rapidly that it is visible only on high speed films. 2.4.2.4 Pulse transfer is a mode of metal transfer somewhat between spray and short circuiting. The specific power source has built into it two output levels: a steady back ground level, and a high output (peak) level. The later permits the transfer of metal across the arc. This peak output is controllable between high and low values up to several hundred cycles per second. The result of such a peak output produces a spray arc below the typical transition current. 2.4.2.4.1 Figure 11 shows the transfer method. The arc is initiated by touching the wire to the work. Upon initial contact, a bit of the wire melts off to form a molten puddle. The wire feeds forward until it actually contacts the work again, as at 1 in Figure 11, and the arc is extinguished. The short circuiting current causes the wire to neck down, as shown in 1, until it melts off, as shown at 2. As soon as the wire is free of the puddle, the arc is reignited and a molten ball forms at the end of the electrode, as at 3. The wire continues to move forward until it makes contact with the puddle, and the cycle is repeated. 2.4.2.5 Gas metal arc spot welding is a variation of the process that allows spot welding of thinner gauge metals, or of a thin gauge metal to a heavier section. The gun is placed directly against the work and is equipped with a special nozzle to allow escape of the shielding gas. When the trigger switch is actuated, the following sequence takes place. The shielding gas flows for a short interval before wire feeding starts; wire feeding starts; the arc is initiated and continues for a preset time (usually a few seconds). The welding current and wire feeding stops, and the shielding gas flows for a short interval before it automatically stops. The process is also useful for tacking welding pieces in position prior to running the final weld 2.4.3 EQUIPMENT AND OPERATION - The equipment used for gas metal arc welding is more complicated than that required for shielded metal arc welding. Initial cost is relatively high, but the cost is rapidly amortized due to the savings in labor and overhead achieved by the rapid weld metal deposition. 2.4.3.1The equipment necessary for gas metal arc welding is listed below: 1) Power source 2) Wire feeder 3) Welding gun 4) Shielding gas supply 5) Solid electrode wire 6) Protective equipment 2.4.3.2The basic equipment necessary for semiautomatic gas metal arc welding is shown

2.4.4 Power Source - A direct current, constant voltage power source is recommended for gas metal arc welding. It may be a transformer-rectifier or a rotary type unit. The lower open circuit voltage and selfcorrecting arc length feature, as described previously , makes it most suitable. Constant voltage power sources used for spray transfer welding and for flux cored electrode welding (to be covered later) are the same. However, if the unit is to be used for short-circuiting arc welding, it must have "slope" or slope control. .

Slope control is a means of limiting the high short-circuit current that is characteristic of this type welder. Figure13 shows the effect of slope on the short-circuiting current. 2.4.4.1 If we were short-arc welding at approximately 150 amperes and 18 volts, as shown in Figure 13,and had no slope components in the power source, the current at short-circuit or when the wire touches the work, would be over 1400 amperes. At this high current, a good length of the wire would literally explode off the end, cause much spatter, and the arc would be erratic. With the slope components in the circuit, the short-circuiting current is in the neighborhood of 400amperes, and the molten ball is sort of pinched off the end of the wire more gently. For those with an electrical background, it might be added that in some machines, slope is

achieved by adding a reactor in the AC secondary of the power source. In others, a slope resistor is addedin the DC output portion of the circuit. Slope may be adjustable for varying wire diameters or itmay be fixed, giving a good average value for .035" and .045" diameter wires, the two most popular sizes. 2.4.4.2 Another factor influencing the arc in short-circuiting welding is the rate that the amperage reaches the short-circuiting current level. Using the example in Figure 13, we know that the current goes from 150 amperes to 400 amperes during each shorting period. If we were to plot the current rise on a graph, as in Figure 14, we would see that the current rise if very rapid, as shown by the broken line. 2.4.4.3This rapid current rise can be by using a device called an(sometimes called a stabilizer)output circuit of the welder. An merely an iron core wound turns of heavy wire. It does current flow, but it acts somewhat like a fly wheel or damper by retarding the rate of rise as shown by the solid line. By preventing the rapid current rise, the arc becomes smoother, spatter is reduced, and bead shape and appearance are improved. Because the inductor influences the time function, its design determines arc on-off time, and short-circuit frequency. Some power sources have a selector that can switch in several different inductance values to finely tune the arc.

2.4.4.4 Welding power sources designed for gas metal arc welding have a 115 volt outlet to provide power to operate the wire feeder. They also have a receptacle to receive the electrical power required to close the main contactor in the power source, which turns on the welding power to the welding gun when the gun trigger is actuated. 2.4.4.5 Additional advancements in equipment technology have introduced many new models. Inverters, as well as microprocessor controls, have created the greatest attention. In addition, multipurpose machines have provided the user with greater flexibility with a variety of capabilities. 2.4.4.6Global competition will continue to have a profound influence on future advancements in arc welding equipment. As energy prices rise, greater demands for more efficient equipment will follow. 2.4.5Wire Feeder - When welding with a constant voltage power source, as is the casein most gas metal arc welding applications, the prime function of the wire feeder is to deliver the welding wire to the arc at a very constant speed. Since the wire feed speed determines the amperage, and the amperage determines the amount of heat at the arc, inconsistent wire feed speed will produce welds of varying penetration and bead width. Advanced electronics technology makes it possible to design motor speed controls that will produce the same speed, even though the load on the motor varies or the input voltage to the motor may fluctuate

.2.4.5.1 A limited amount of gas metal arc welding is performed with constant current type power sources. In this case, the motor speed automatically varies to increase or decrease thewire feed speed as the arc length varies to maintain a constant voltage. 2.4.5.2 The wire feeder also controls the main contactor in the power source for safety reasons. This assures that the welding wire will only be energized when the switch on the welding gun is depressed. 2.4.5.3 The flow of shielding gas is controlled by a solenoid valve (magnetic valve) in the wire feeder to turn the shielding gas on and off when the gun switch is actuated. Most feeders utilize a dynamic breaking circuit to quickly stop the motor at the end of a weld to prevent along length of wire protruding from the gun when the weld is terminated. Most feeders have a burn-back circuit that allows the welding current to stay on for a short period of time after wire feeding has stopped, to allow the wire to burn back exactly the right amount for the next arc initiation .2.4.5.4The feed rolls, sometimes called drive rolls, pull the wire off the spool or reel, and push it through a feed cable or conduit to the welding gun. These rolls must usually be changed to accommodate each different wire diameter, although some rolls are designed to feed a combination of sizes .2.4.6 Welding Gun - The function of the welding gun, sometimes referred to as a torch, is to deliver the welding wire, welding current, and shielding gas to the welding arc. Guns are available for semi-automatic operation and for automatic operation, where they are fixed in the automatic welding head .2.4.6.1 Guns for GMAW have several characteristics in common. All have a copper alloy shielding gas nozzle, that delivers the gas to the arc area in a non turbulent, angular pattern to prevent aspiration of air. The nozzle may be water cooled for semiautomatic welding at high amperage and for automatic welding where the arc time is of long duration. Welding current is transferred to the welding wire as the wire travels through the contact tip or contact tube located inside the gas nozzle (Refer to Figure 9). The hole in the contact tip through which the wire passes is only a few thousandths of an inch larger than the wire diameter. A worn contact tip will result in an erratic arc due to poor current transfer. Figure 15 shows a few different semiautomatic gun configurations that are commonly used for GMAW.

2.4.6.2The curved neck or "goose neck" type is probably the most commonly used. It allows the best access to a variety of weld joints. The wire is pushed to this type of gun by the feed rolls in the wire feeder through a feed cable or conduit that usually is 10 or 12 feet in length. The shielding gas hose, welding current cable, and trigger switch leads are supplied with the welding gun

.2.4.6.3 The pistol type gun is similar to the curved neck type, but is less adaptable for difficult to reach joints. The pistol type is also a "push" type gun and is more suitable for gas metal arc spot welding applications. 2.4.6.4The self contained type has an electric motor in the handle and feed rolls that pull the wire from a 1 or 2 pound spool mounted on the gun. The need for a long wire feed cable is eliminated, and wire feed speed may be controlled by the gun. Guns of this type are often used for aluminum wire up to .045" diameter, although they may also be used for feeding steel or other hard wires .2.4.6.5The pull type gun has either an electric motor or an air motor mounted in the handle that is coupled to a feeding mechanism in the gun. The spool of wire is located in the control cabinet that may be located as far as fifty feet from the gun. When feeding such long distances, a set of "push" rolls located in the control cabinet assist in feeding the wire. This then becomes known as a push-pull feed system and is especially useful in feeding the softer wires such as aluminum. 2.4.7SHIELDING GASES - In gas metal arc welding, there are a variety of shielding gases that can be used, either alone or in combinations of varying degrees. The choice is dependent on the type of metal transfer employed, the type and thickness of metal, the bead profile (See Figure 16), penetration, and speed of welding. In our discussion, we will deal with the more common choices used for the various transfer processes

2.4.7.1Short Circuiting Transfer - Straight carbon dioxide (CO2) is often used for short circuiting arc welding because of its low cost. The deep penetration usually associated withCO2 is minimized because of the low amperage and voltage settings used with this process. Compared to other gas mixes, CO2 will produce a harsher arc and therefore, greater spatter levels. Usually, this is minimized by maintaining a short arc length and by careful adjustment of the power supply inductance. The temperatures reached in welding will cause carbon dioxide to decompose into carbon monoxide and oxygen. To reduce the possibility of porosity caused by entrapped oxygen in the weld metal, it is wise to use electrodes that contain deoxidizing elements, such as silicon and manganese. If the current is increased above the short circuiting range, the use of carbon dioxide tends to produce a globular transfer .2.4.7.1.1 Mixing argon in proportions of 50-75% with carbon dioxide will produce a smoother arc and reduce spatter levels. It will also widen the bead profile, reduce penetration, and encourage "wetting". Wetting, i.e., a uniform fusion, along with joining edges of the base metal and the weld metal, minimizes the weld imperfection known as undercutting (See Figure 17).

2.4.7.1.2 The 75% Argon/25 CO2 mixture is often chosen for short circuit welding of thin sections, whereas the 50-50 combination works well on thicker sections. 2.4.7.1.3 It should be noted that shielding gases can affect the metallurgy of the weld metal .As an example, a combination of argon and carbon dioxide may be used for welding stainless steel, but as the carbon dioxide breaks down, excessive carbon may be transferred into the weld metal. Corrosion resistance in stainless steel is reduced as the carbon content increases. To counteract this possibility, a less reactive mixture of 90% helium - 7-1/2% argon- 2-1/2% CO2 is sometimes chosen. This combination, known as a trimix, provides good arc stability and wetting .2.4.7.2Spray Arc Transfer - Pure argon produces a deep constricted penetration at the center of the bead with much shallower penetration at the edges (Figure 16). Argon performs well on nonferrous metals, but when used on ferrous metals, the transfer is somewhat erratic with the tendency for the weld metal to move away from the center line. To make argon suit-able for spray transfer on ferrous metals, small additions of 1 to 5% oxygen have proven to provide remarkable improvements. The arc stabilizes, becomes less spattery, and the weld metal wets out nicely. If the percentage of argon falls below 80%, it is impossible to achieve true spray transfer .2.4.7.2.1 Pure helium or combinations of helium and argon are used for welding no ferrous metals. The bead profile will broaden as the concentration of helium increases. 2.4.7.3Pulse Spray Transfer - The selection of shielding gas must be adequate enough to support a spray transfer. Material type, thickness, and welding position are essential variable sin selecting a particular shielding gas. The following is a list of recommended gases: Carbon Steel Argon/CO2/O2/He (He less than 50%) Alloy Steel Argon/CO2/O2/He (He less than 50%) Stainless Argon/O2/CO2 (CO2 max. 2%) Copper, Nickel, & Cu-Ni Alloys Argon/Helium Aluminum Argon/Helium 2.4.8Electrodes - The solid electrodes used in GMAW are of high purity when they come from the mill. Their chemistry must be closely controlled and some types purposely contain high levels of deoxidizers for use with CO2 shielding. 2.4.8.1The electrode manufacturer draws down the electrode to a finished diameter that, with GMAW, is usually quite small. Diameters from .030" thru 1/16" are common. 2.4.8.2Most steel GMAW electrodes are copper plated as a means of protecting the surface. The copper inhibits rusting, provides smooth feeding, and helps electrical conductivity. 2.4.8.3Information on types and classifications will be covered in a future lesson.

2.5FLUX CORED ARC WELDING

Flux Cored Arc Welding (FCAW) is quite similar to GMAW as far as operation and equipment are concerned. The major difference is that FCAW utilizes an electrode that is very different from the solid electrode used in GMAW. The flux cored electrode is a fabricated electrode and as the name implies, flux material is deposited into its core. The flux cored electrode begins as a flat metal strip that is formed first into a "U" shape. Flux and alloying elements are deposited into the "U" and then the shape is closed into a tubular configuration by a series of forming rolls. 2.5.0.1The flux cored electrode is a continuous electrode that is fed into the arc where it is melted and transferred into the molten puddle. As in GMAW, the flux cored process depends on a gas shield to protect the weld zone from detrimental atmospheric contamination. With FCAW, there are two primary ways this is accomplished (See Figure 18). The gas is either applied externally, in which case the electrode is referred to as a gas shielded flux cored electrode, or it is generated from the decomposition of gas forming ingredients contained in the electrode's core. In this instance, the electrode is known as a self-shielding flux cored electrode. In addition to the gas shield, the flux cored electrode produces a slag covering for electrode. In addition to the gas shield, the flux cored electrode produces a slag covering for further protection of the weld metal as it cools. The slag is manually removed with a wire brush or chipping hammer .2.5.1Self Shielded Process - The main advantage of the self shielding method is thatits operation is somewhat simplified because of the absence of external shielding equipment.

2.5.1Self Shielded Process - The main advantage of the self shielding method is that its operation is somewhat simplified because of the absence of external shielding equipment. Although self shielding electrodes have been developed for welding low alloy and stainless steels, they are most widely used on mild steels. The self shielding method generally uses along electrical stick-out (distance between the contact tube and the end of the un melted electrode) commonly from one to four inches. Electrical resistance is increased with the long extension, preheating the electrode before it is fed into the arc. This enables the electrode to burn off at a faster rate and increases deposition. The preheating also decreases the heat available for melting the base metal, resulting in a more shallow penetration than the gas shielded process .2.5.1.1 A major drawback of the self shielded process is the metallurgical quality of the deposited weld metal. In addition to gaining its shielding ability from gas forming ingredients in the core, the self shielded

electrode contains a high level of deoxidizing and denitrifying alloys, primarily aluminum, in its core. Although the aluminum performs well in neutralizing the affects of oxygen and nitrogen in the arc zone, its presence in the weld metal will reduce ductility and impact strength at low temperatures. For this reason, the self shielding method is usually restricted to less critical applications. 2.5.1.2 The self shielding electrodes are more suitable for welding in drafty locations thant he gas shielded types. Since the molten filler metal is on the outside of the flux, the gases formed by the decomposing flux are not totally relied upon to shield the arc from the atmosphere. The deoxidizing and denitrifying elements in the flux further help to neutralize the affects of nitrogen and oxygen present in the weld zone. 2.5.2The Gas Shielded Process - A major advantage with the shielded flux cored electrode is the protective envelope formed by the auxiliary gas shield around the molten puddle. This envelope effectively excludes the natural gases in the atmosphere without the need for core ingredients such as aluminum. Because of this more thorough shielding, the weld metallurgy is cleaner which makes this process suitable for welding not only mild steels, but also low alloy steels in a wide range of strength and impact levels. 2.5.2.1The gas shielded method uses a shorter electrical stick out than the self shielded process. Extensions from 1/2" to 3/4" are common on all diameters, and 3/4" to 1-1/2" on larger diameters. Higher welding currents are also used with this process, enabling high deposition rates to be reached. The auxiliary shielding helps to reduce the arc energy into a columnar pattern. The combination of high currents and the action of the shielding gas contributes to the deep penetration inherent with this process. Both spray and globular transfer are utilized with the gas shielded process. 2.5.3 Current Density - Flux cored arc welding utilizes the same principles of current density, as explained in section 2.4.1, but there is one significant difference between the flux cored electrode and the solid electrode. With the flux cored electrode, the granular core ingredients are poor electrical conductors and therefore, the current is carried primarily through the outer metal sheathing. When an equal diameter cross section of the two are compared (See Figure19), it is seen that the flux cored electrode has a smaller current carrying area than the solid electrode. This greater concentration of current in a smaller area increases the burn off rate.

2.5.3.1When all other factors are equal ,the deposition rate of the flux cored electrode is somewhat higher than the solid electrode. 2.5.4EQUIPMENT - The equipment used for flux cored arc welding is the same as shown previously in Section 2.3.2.2, Figure 12, with the exception that the self shielded method does not need the external gas apparatus. 2.5.4.1Flux cored arc welding is done with direct current. All of the gas shielded electrodes are designed for DCEP operation. The self shielded electrodes are either designed specifically for DCEN or DCEP.

2.5.5Power Source - The recommended power source is the direct current constant voltage type. The constant current type can be used but with less satisfactory results. 2.5.6Wire Feeder - The function of the wire feeder in FCAW is the same as discussed in the section on GMAW. Since the flux cored electrode is tubular in construction, precautions must be taken not to flatten the electrode. To facilitate feeding by means other than pressure alone, specially designed feed rolls with knurled or grooved surfaces are used. Some feeders use four feed rolls rather than two to minimize unit pressure on the electrode. 2.5.7The Welding Gun - As compared to GMAW, the main difference in FCAW welding guns is in those used with the self shielding process. The gun is somewhat more compact due to the absence of an external gas shielding nozzle. Since the self shielding process normally requires a longer electrode extension, the self shielding gun may have an insulated guide tube(Refer back to Figure 18) to give stability to the electrode. Water cooled guns are available for high duty semi-automatic welding and for automatic welding. 2.5.7.1Flux cored welding generates fumes, that for environmental reasons, must be removed from the welding area. This is usually done with an external exhaust system, but welding guns with internal fume extractors have been developed. They are heavier than the regular gun and must be properly maintained so that the extracting mechanism does not disturb the shielding gas. 2.5.8SHIELDING GASES - Carbon dioxide is the most widely used gas for auxiliary shielding of the flux cored electrode. The other commonly used gas is a mixture of 75% Argon and 25% CO2. 2.5.8.1A carbon dioxide shield produces deep penetration and the transfer is globular. As previously discussed, CO2 will dissociate in the heat of the arc. To counteract this characteristic, deoxidizing elements are added to the core ingredients of the electrode. The deoxidizers react to form solid oxide compounds that float to the surface as part of the slag covering. 2.5.8.2The addition of Argon to CO2 will increase the wetting action, produce a smooth arc , and reduce spatter. The transfer is spray-like, and the penetration is somewhat less thanwith the straight carbon dioxide .2.5.8.3While some flux cored electrodes are designed to operate well on both the 100%CO2 or the 75/25 mixture, others are formulated specifically for the CO2 shield or the Argon/CO2 mixture. If the recommended gas is not used with these electrodes, the weld chemistry may be affected. The reason for this is that inert gas, such as Argon, does not react with the other elements; therefore, allowing them to be transferred across the arc into the weld metal. An electrode designed for CO2 shielding contains deoxidizing elements, such as silicon and manganese. If a high percentage of Argon is used in the shielding medium, a large portion o these elements may pass into the weld metal causing the weld metallurgy to be less ductile than intended . 2.5.8.3 The opposite happens with electrodes formulated for a 75/25 mixture. These electrodes are usually designed for high yield and tensile strength. If a high percentage of CO2is used with them, the CO2 may react with the elements needed to attain these strength levels ,thereby preventing them from passing into the weld metal.

2.6SUBMERGED ARC WELDING

Submerged Arc Welding (SAW) is different from the previously explained arc welding processes in that the arc is not visible. The arc is submerged beneath loose granular flux. A continuous electrode is fed by automatic drive rolls through an electrode holder where current is picked up at the contact tube. The electrode moves into the loose flux and the arc is initiated. The flux is deposited from a separate container that moves at the same pace as the electrode assuring complete coverage (See Figure20). 2.6.1Submerged Arc Flux - The flux helps form the molten puddle, slows the cooling rate, and acts as a protective shield. The flux, which is in close contact with the arc, is fused into a slag cover and that which is not fused is collected for reuse. The flux can contain alloying elements that, when molten, will pass into the weld metal affecting the metallurgy. Some fluxes are specifically prepared for their alloy altering capabilities while others, known as neutral fluxes, are chosen when a minimal alloy change is desired. Although these latter fluxes are called "neutral", they still have the ability to slightly alter the weld chemistry

L2.6.2

The Welding Gun - Although there are hand-held welding guns for the submerged arc process, the majority of SAW is done with fully automatic equipment. The basic components include a wire feeder, a power source, a flux delivery system, and in some instances, an automatic flux recovery system.

2.6.3Power Sources - The power source can be a constant current AC transformer, or it may be a DC rectifier or generator of either the constant current or constant voltage variety. The power source must be rated for high current output. When current requirements exceed the value of a single machine, two or more of the same type may be connected in parallel. 2.6.4Equipment - Most submerged arc welding is done with DCEP because it provides easy arc starting, deep penetration and excellent bead shape. DCEN provides the highest deposition rates but minimum penetration. Alternating current is often used as a trailing arc I tandem arc applications. In this type of application, the leading DCEP arc provides deep penetration, and the closely trailing AC arc provides high deposition with a minimum of arc blow. 2.6.5Electrodes - A variety of ferrous and nonferrous electrodes are used in submerged arc welding. They are usually solid electrodes refined with the appropriate alloys at the steel mill, and then shipped to electrode manufacturers where they are drawn down to a specific diameter and packaged. There is another type of sub arc electrode known as a composite electrode, that is fabricated in the same manner as a flux cored electrode. A chief advantage of this type is that the alloying elements can be added to the core of the electrode more cheaply than a steel mill can produce those same alloys in a solid form. The electrodes for SAW vary in diameter from 1/16 inch to 1/4 inch with the larger diameters being the most widely used. 2.6.6Summary - Submerged arc welding has some advantages over other welding processes. Since the radiance of the arc is blanketed by the loose flux, there is no need for a protective welding hood (although safety glasses are recommended), there is no spatter and only a very minimal amount of fumes escape from under the blanket. High welding currents quite commonly in the 300 to 1600 ampere range, are used. These

high currents, combined with fast travel speeds, make SAW a high deposition process that is especially suitable for applications that require a series of repetitious welds. Some setups allow two or more electrodes to be fed simultaneously into the joint, further increasing the deposition rate and speed. 2.6.6.1Although SAW has these advantages, it does have some limitations. The flux must be deposited and collected for every welding pass. This requires additional equipment and handling. Also because of the loose flux, the process is limited to the flat and horizontal positions. The equipment for SAW is commonly quite bulky which limits its mobility, and although the process works well on thick materials, it usually is not satisfactory for thin gauge material. The process requires care in the operation. The amperages commonly used may cause excessive heat buildup in the base metal, that may result in distortion or brittleness. GLOSSARY OF TERMS Arc Blow- Deviation of the direction of the welding arc caused by magnetic fields in the work piece when welding with direct current. Straight Polarity- Welding condition when the electrode is connected to the negative terminal and the work is connected to the positive terminal of the welding power source. Reverse Polarity- Welding condition when the electrode is connected to the positive terminal and the work is connected to the negative terminal of the welding power source. Slag- The brittle mass that forms over the weld bead on welds made with coated electrodes, flux cored electrodes, submerged arc welding and other slag producing welding processes. Welds made with the gas metal arc and the gas tungsten arc welding processes are slag free. Manual Arc Welding- Welding with a coated electrode where the operator's hand controls travel speed and the rate the electrode is fed into the arc. Semi-Automatic Welding- Welding with a continuous solid wire or flux cored electrode where the wire feed speed, shielding gas flow rate, and voltage are preset on the equipment, and the operator guides the hand held welding gun along the joint to be welded. Slag Inclusion- A weld defect where slag is entrapped in the weld metal before it can float to the surface. Root Pass- The initial pass in a multi-pass weld, usually requiring 100% penetration. Gas Ions- Shielding gas atoms that, in the presence of an electrical current, lose one or more electrons and therefore, carry a positive electrical charge. The provide a more electrically conductive path for the arc between the electrode and the work piece. High Frequency- (as applied to gas-tungsten arc welding)An alternating current consisting of over 50,000 cycles per second at high voltage, low amperage that is superimposed on the welding circuit in GTAW power sources. It ionizes a path for non-touch arc starting and stabilizes the arc when welding with alternating current. Inert Gases- Gases that are chemically inactive. They do not readily combine with other elements. Flux- In arc welding, fluxes are formulations that, when subjected to the arc, act asa cleaning agent by dissolving oxides, releasing trapped gases and slag and generally cleaning the weld metal by floating the impurities to the surface where they solidify in the slag covering. The flux also serves to reduce spatter and contributes to weld bead shape. The flux may be the coating on the electrode, inside the electrode as in flux cored types, or in a granular form as used in submerged arc welding. Current Density- The amperes per square inch of cross-sectional area of an electrode. High current density results in high electrode melt-off rate and a concentrated, deep penetrating arc. Slope or Slope Control- A necessary feature in welding power sources used for short circuiting arc welding. Slope Control reduces the short circuiting current each time the electrode touches the weld puddle Inductance- (as applies to short circuiting arc welding)A feature in welding power sources designed for short circuiting arc welding to retard the rate of current rise each time the electrode touches the weld Contact Tip- That part of a gas metal arc welding gun or flux cored arc welding gun that transfers the welding current to the welding wire immediately before the wire enters the arc. Spray Transfer- Mode of metal transfer across the arc where the molten metal droplets are smaller than the electrode diameter and are axially directed to the weld puddle .Requires high voltage and amperage settings and a shielding gas of at least80% argon. Globular Transfer- Mode of metal transfer across the arc where a molten ball larger than the electrode diameter forms at the tip of the electrode. On detachment, it take son an irregular shape and tumbles towards

the weld puddle some times shorting between the electrode and work at irregular intervals. Occurs when using shielding gases other than those consisting of at least 80% argon andat medium current setting Pulse Transfer- Mode of metal transfer somewhat between spray and short circuiting. The specific power source has built into it two output levels: a steady back ground level, and a high output (peak) level. The later permits the transfer of metal across the arc. This peak output is controllable between high and low values up to several hundred cycles per second. The result of such a peak out put produces a spray arc below the typical transition current. Short-circuiting Transfer- Mode of metal transfer in gas metal arc welding at low voltage and amperage. Transfer takes place each time the electrode touches or short-circuits to the weld puddle, extinguishing the arc. The short-circuiting current causes the electrode to neck down, melt off, and then repeats the cycle. Trimix or Triple Mix- A shielding gas consisting of approximately 90% helium, 7-1/2% argon, and21/2% carbon dioxide used primarily for short-circuiting arc welding of stainless steels. Maintains corrosion resistance of the stainless steel and produces good wetting and excellent weld bead shape. Electrical Stick-Out- In any welding process using a solid or flux cored wire, the electrical stick-out is the distance from the contact tip to the un melted electrode end. Some times called the "amount of wire in resistance". This distance influences melt-off rate, penetration, and weld bead shape. Out-of-Position Welds- Welds made in positions other than flat or horizontal fillets